According to Au7o's analysis of 680+ owner reports, the 2002 Ford Excursion has 2 documented known issues, with 1 rated critical. The most serious is BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models) ($350-$5,000 repair). The most commonly reported issue is BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models) with 680 owner reports. Across all issues, repair costs range from $250 to $5,000. DIY maintenance guides at au7o.io.
On the 2000-2005 Ford Excursion 6.8L V10, the 2000-2005 Ford Excursion equipped with the 6.8L V10 engine and BorgWarner 4405 electric-shift-on-the-fly transfer case experiences multiple failure modes including transfer case shift motor failure, false neutral conditions, and GEM (Generic Electronic Module) control issues. The electric shift motor can become stuck in intermediate positions between 2WD and 4WD, causing a false neutral condition where no drive torque reaches the wheels. The GEM module that controls 4WD engagement can fail or lose communication, preventing 4WD operation entirely. JustAnswer.com and Ford Expedition Forum document cases where the transfer case shifts to neutral unexpectedly. RepairPal estimates the transfer case shift motor replacement cost between $346 and $420, but complete transfer case overhaul or replacement can cost $3,000-5,000.
Common Symptoms
Transfer case stuck between 2WD and 4WD (false neutral)
4WD indicator light flashing or not illuminating
No response when shifting from 2H to 4H or 4L
Grinding or clunking when engaging 4WD
Vehicle loses all drive torque unexpectedly
GEM module 4x4 fault codes
Transfer case shift motor running but not completing shift
Difficulty shifting from 4L back to 2H
How to Fix
Diagnose using GEM module DTCs first - many issues are electrical (shift motor or GEM) rather than mechanical. The shift motor (Dorman 600-805 or Motorcraft) is the most commonly replaced component at $200-350 plus 1-2 hours labor. If the GEM module has failed, replacement and programming ($300-600) is required at a dealer. For mechanical transfer case issues (grinding, worn chains), a complete rebuild ($2,000-3,500) or remanufactured replacement ($2,500-5,000 installed) is needed. Change transfer case fluid every 30,000 miles with Mercon V.
What Owners Are Using
Parts and tips from 680+ owners who fixed this issue
TipMost V10 Excursion transfer case "failures" are actually the electric shift motor or GEM module, not the transfer case itself. Diagnose the electrical components first before authorizing expensive transfer case work. The shift motor is accessible without dropping the transfer case.
NoteIf the transfer case drops to neutral at highway speed, you lose all drive torque instantly - this is a safety hazard. If you experience even one false neutral event, do not drive the vehicle until the transfer case system is diagnosed and repaired.
Medium Confidence680 reportsLast reported by owners Feb 2026Reviewed Feb 2026
On the 2000-2005 Ford Excursion, the front hub bearings wear prematurely due to the vehicle's extreme weight (7,600+ lbs GVWR). Symptoms include humming noise that changes with speed and steering wheel vibration. Common on both 4x2 and 4x4 models.
Medium Confidence0 reportsLast reported by owners Invalid DateReviewed Invalid Date
⚠️NHTSA Recalls11 recalls
EXTERIOR LIGHTING:TAIL LIGHTS
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
Campaign #11V35200013/07/2011
ELECTRICAL SYSTEM:WIRING
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Campaign #05V27000010/06/2005
VEHICLE SPEED CONTROL
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Campaign #09V39900013/10/2009
VEHICLE SPEED CONTROL
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Campaign #07V07800006/03/2007
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.
According to Au7o's analysis of 680+ owner reports, the 2002-2002 Ford Excursion has 2 documented issues. The most frequently reported are: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), Front Wheel Hub and Bearing Assembly Failure. Of these, 1 is rated critical and should be addressed promptly.
Is the Ford Excursion reliable?
The 2002-2002 Ford Excursion has 2 known issues documented across 680+ owner reports. 1 issue is rated critical: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford Excursion problems?
Repair costs for known Ford Excursion issues range from $250 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), typically costs $350-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2000-2005 Ford Excursion BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models)?
The 2000-2005 Ford Excursion equipped with the 6.8L V10 engine and BorgWarner 4405 electric-shift-on-the-fly transfer case experiences multiple failure modes including transfer case shift motor failure, false neutral conditions, and GEM (Generic Electronic Module) control issues. Repairs typically run $350-$5,000. Severity: high.
What is the 2000-2005 Ford Excursion Front Wheel Hub and Bearing Assembly Failure?
The front hub bearings wear prematurely due to the vehicle's extreme weight (7,600+ lbs GVWR). Symptoms include humming noise that changes with speed and steering wheel vibration. Common on both 4x2 and 4x4 models. Repairs typically run $250-$500. Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
